Building sheathing elements



Sept. 3, 1968 J PAYNE ET AL 3,399,503

BUILDING SHEATHING ELEMENTS Filed April 17, 1967 -FIG. 1.

IN VENT 0R HAROLD J. W. PAYNE CLIFFORD E. D

3,399,503 BUILDING SHEATHING ELEMENTS Harold James William Payne, RabyMere, England, and

Clifford Edward Dyer, Waterloo, Belgium, assignors to H. H. RobertsonCompany, Pittsburgh, Pa., a corporation of Pennsylvania Filed Apr. 17,1967, Ser. No. 631,215 Claims priority, application Great Britain, Apr.16, 1966,

16,790/ 66 8 Claims. (Cl. 52-406) ABSTRACT OF THE DISCLOSURE Aprefabricated, insulated building panel formed from an inner liner sheetand a fluted outer facing sheet with side edges of both sheets engagedto allow overlapping connection of the assembled panels in side-by-siderelation on a building outer surface. The panels contain foamed-in-situinsulation which serves as thermal and sound insulation and serve torigidify the panel. The foamed-in-situ insulation may fill less than allof the volume of the fluted outer facing sheet.

Background of the invention Field of invention-This invention relates tothe cladding of roofs and walls and more particularly, but of course notexclusively, the roofs and walls of industrial buildings, and has forits object to provide a composite wall or roof sheathing element whichmay be assembled and erected in more or less the same fashion asconventional corrugated cladding or sheathing elements but which willpossess effective sound and heat insulating properties and constitutes agood fire barrier.

Description of the prior art.Shop assembled building panels with innerand outer sheets have been proposed having interlocking side-to-sidejunctions. Building sheathing has been proposed using abutting linersections connected on the building site to fluted facing sheets. Shopassembled building panels with inner and outer sheets have been proposedhaving interior transverse subgirts to connect inner and outer sheets.

Summary of the invention This invention provides a prefabricatedbuilding sheathing panel having an inner liner sheet and an outer flutedfacing sheet wherein the two sheets are engaged along their side edges.

Broadly, according to the invention, and in one mode of embodiment, asheathing element for the purpose specified comprises a facing sheet, abacking sheet, and bonded therebetween a layer of rigid foamed plasticsmaterial, e.g. polyurethane; said backing sheet being in the form of ashallow, generally channel-shaped member, and said facing sheet being ofcorrugated profile. Preferably, but not essentially, the flutes orchannels of the facing sheet extend in the same direction as the sidewalls of the backing sheet. The upper edges of the side walls of saidbacking sheet may be turned both in the same direction to form flangesone of which extends inwardly of the trough of said channel and theother outwardly thereof, and the corrugated facing sheet may haveterminal side edges which overlie said flanges. Preferably, one end ofsaid facing sheet is arranged so as to extend beyond the adjacent endsof the rigid foamed core and said backing sheet. Thus constructed, saidsheathing elements may be assembled in overlapped weatherproofrelationship.

Brief description of the drawing The invention is further described withthe aid of the accompanying explanatory drawing which illustrate by3,399,503 Patented Sept. 3, 1968 "ice way of example and not oflimitation an example of same.

In said drawings:

FIGURE 1 depicts in cross-section a sheathing element assembled withfellow elements, and

FIGURE 2 is a fragmentary sectional view as on line 11-11 of FIGURE 1.

Description of the preferred embodiment Referring to said drawings, thecharacter A generally denotes the backing sheet of a wall or roofsheathing element, B the facing or front sheet thereof, and C an innerlayer of rigid foamed polyurethane.

The backing sheet A consists of a generally channel section membercomprising a tension flange or web 10, and side walls 12, 14. Said sidewalls, which may or may not extend normal to the tension flange or web10, are formed with flanges 16, 18 which extend both in the samedirection as shown parallel or substantially so to the flange or web 10.Said sheet may be composed of any suitable material, e.g. mild steelsheeting treated so as to be resistant to corrosion or a non-ferrousmetal or metal alloy.

The facing or front sheet B also may be composed of sheet metal or metalalloy, and may be of any desired corrugated profile. In the exampleshown the sheet is formed as by rolling or pressing with a plurality ofsubstantially uniformly spaced flutes or channels 20 the sides andbottoms whereof are of planar construction. At one side the sheet B isformed with a flange 22 arranged so as to overlie the flange 16 of thebacking sheet A, and the flange 22 is terminated with a turned down lip24 which extends beyond said flange 16. At its other side said sheet Bterminates at a flange 26 which overlies the flange 18 of sheet A butdoes not extend beyond same. Said flange 26 is depicted as being ofconcave cross-section but may be planar.

It also is arranged for the facing sheet B to extend beyond the end ofthe sheet A and the core C at one end as at 28 in FIGURE 2 thereby toprovide for an overlapping assembly of the facing sheets B with thefacing sheets of adjacent fellow sheathing elements according to theinvention.

The core C preferably is foamed in situ in the member A and the sheet Bplaced in position during the foaming operation whereby said sheetsbecome bonded firmly together. In order to obviate the buildup of unduepressures between sheets A and B during the foaming therebetween of thecore C, it may be arranged for the spaces 30 between each channel 22 toremain unfilled as shown. Alternatively, said core C may be preformedand subsequently bonded in position by means of an adhesive.

It will be seen that sheathing elements according to the invention maybe employed with advantage in the cladding of roof and wall structuresand will obviate the necessity for the separate provision of innersheathing elements and intervening insulating bats. Adjacent elementsmay be connected one to the other by fastening means, eg screws orbolts, inserted through the overlapped flange parts at the pointsindicated by the numeral 32 in FIGURE 1. The elements may be secured toa supporting structure by fastening means passed therethrough asindicated at 34.

We claim:

1. A prefabricated insulated building panel adapted to be erected inside-by-side overlapping relation to form a wall, comprising a generally-U-shaped inne-r liner sheet having an essentially flat web andupstanding sidewalls terminating in first and second marginal flanges,said first marginal flange projecting inwardly over said web and saidsecond marginal flange projecting outwardly away from said web;

a fluted outer facing sheet overlying said liner sheet and havingalternating crests and valleys, said facing sheet having a crest at onelongitudinal side thereof which overlies and engages said first flangeand a crest at its opposite longitudinal side which overlies and engagessaid second marginal flange; and

a core of foamed insulating material bonding said liner sheet to saidfacing sheet;

said second flange being closer to said web than said first flange toallow overlapping engagement of one said building panel with adjacentbuilding panels.

2. The building panel of claim 1 wherein the crest engaging said secondflange has an arcuate cross-section.

3. The building panel of claim 2 wherein the crest engaging said secondflange is exteriorly concave.

4. The building panel of claim 1 wherein said core comprises afoamed-in-situ insulating material.

5. The building panel of claim 4 wherein said foamedin-situ insulatingmaterial fills the space between said web of said inner liner sheet andsaid valleys of said outer facing sheet.

6. The building panel of claiml wherein said firstand second flanges aredisposed outwardly beyond said valleys of said outer facing sheet.

7. The building panel of claim 6 wherein said first marginal flange isdisposed outwardly from the said second marginal flange by distancecorresponding to/the thickness of the crest engaged with said secondflange.

8. The building panel of claim 1 wherein adjoining panels are assembledby means of a fastener extending sequentially through a crest and anengaged marginal flange of one panel and a crest and an engaged marginalflange of the adjoining panel.

References Cited UNITED STATES PATENTS 3,062,337 11/1962 Zittle 52 537FRANK L. ABBOTT, Primary Examiner.

S. D. BURKE, Assistant Examiner.

